BL20 Codesys Gateway Controls Image Processing Machine
The PALC unit image processing systems from ISW use Turck’s Codesys programmable BL20 gateway to check data matrix codes and plain text
The advanced image processing systems manufactured by the German company Industrielle Sensorsysteme Wichmann GmbH (ISW) are used in all sectors of industry. In the machines of the PALC unit series, Turck’s Codesys-programmable BL20 gateway processes the signals of different sensors and devices, operating as a PLC and coordinating the functions of the subsystems. The simple programming and optimum dimensions for this application were some of the key factors in choosing the BL20 system.
The PALC unit (Package Aggregation Line Controller) is mostly used in the pharmaceutical sector. In its standard application, the machine marks a folded box with a unique serial number, product specific data and a data matrix code. It then checks the quality of the print. This is necessary to guarantee readability at the end customer (i.e., in the drugstore).
The PALC unit consists of a conveyor belt which feeds the folded boxes to a camera with a lighting system. A photoelectric sensor at the entry initiates a start trigger for the printing and measuring process. This is combined with another signal from a rotary encoder at the motor, which triggers the printer and camera at the right time. The camera checks the quality of the print on the basis of parameters taught. If the print result does match the target values, a compressed air nozzle blows this folded box from the conveyor belt to a reject chute. Another photoelectric sensor triggers the compressed air nozzle to blow the bad boxes (NOK) from the belt into the reject chute.
Easy Handling
Both photoelectric sensors are from Banner Engineering, Turck’s partner for optoelectronic solutions. The simplicity of the system is also its strength: “We didn’t have to teach the system or do anything similar. The photoelectric sensor is fitted with a reflector to act as a reflex sensor. Any foreground or background rejection is unnecessary here,” Tobias Wichmann says. The Turck compressed air sensor (M12E-VP44X-H1141), which is located at the maintenance unit of the compressed air nozzle and monitors the compressed air present as required, also offers easy handling.
Codesys Gateway as PLC
“The PLC is the core of the system,” says ISW representative Wichmann. In this case, it’s the programmable BL20 gateway from Turck that handles the control task. “All signals come together on the PLC and are processed: the signals of the IPC, the sensors, trigger signals, signals of the camera inspection and compressed air monitor and more,” Wichmann continues. “Turck’s Codesys programmable BL20 gateway has exactly the right dimensions for this task. Naturally, the PLCs of major manufacturers could also handle this task but would be unnecessarily expensive and complex. Another benefit was the fact that we already had experience with Codesys in the company and could program our solution quickly with the BL20. The choice of a suitable controller for the PALC was therefore easy to make.” The communication between the industrial PC and the gateway is implemented via a TCP/IP Ethernet connection.
- Automotive
- Motor Control with Condition Monitoring
- IP67 Hybrid Module Processes Safety Signals
- Decentralized monitoring of cooling stations
- Roboterschweißzellen mit Ethernet vernetzt
- Monitoring the cooling circuit on welding clamps
- Flow monitoring in drum washers
- Sheet Metal Thickness Measurement
- Condition Monitoring of Motors
- Cloud-based level monitoring
- Press Shop – Tool Identification
- Body Shop – Welding Nut Detection
- Paint Shop – Skid Identification
- Final Assembly – Robot Assembly
- Tier 1 – Bumper Identification
- Powertrain – Contactless Verification
- Body Detection in Automobile Production
- Area Guarding for Robotic Cells
- Item-level Detection with UHF RFID
- Supply of cooling lubricant in machine tools
- Controlling hydraulic pressure in pressing plants
- Measuring process pressure on scissor lifts
- Inspection of Tips on a Welder
- Manual Feeding in Weld Cell
- Detecting Black Parts on Black Door Panel
- Moonroof Clear Glass Detection
- Long-Range Inspection in Automotive Assembly
- Rubber Washer Detection on Engine Block
- Engine Block Part-In-Place Detection
- Electric Vehicle Detection in Charging Station
- Vehicle Detection in a Self-Serve Car Wash
- Success Stories
- Laser Sensor Detects Black Bumpers in Assembly Cell
- Decentralized Safety Technology for Modular Production
- Modular Conveyor System
- RFID and I/O modules for Safe Tool Changes
- RFID Guides AGV in Suspension Production
- IO-Link Wired Silencer Production
- Workpiece Carrier Identification in Rear Vent Production
- Weld Nut Sensing
- RFID Traceability
- RFID in Engine Production
- Bumper Production with Identification
- Solutions for Paint Shops
- Welding and Assembly Sensors
- Angle Sensors for Assembly Systems
- Tool Identification
- Pick-to-Light for Bumper Assembly
- RFID Identification of Injector Nozzles
- RFID in the Body Shop
- Ply Orientation Inspection
- IO-Link Eases Differential Gear Production
- Chemical
- Ethernet Signal Connection in the I&C Room
- Ethernet-based Automation of Modular Skids
- Ex Isolation in Modular Process Plants
- Detection of Pigs
- Remote Signal I/O
- Remote Tank Level Monitoring with DX70
- Easy Connection of Field Devices
- Signal Processing with System I/O in the Control Cabinet
- Signal Separation with Interface Technology in the Control Cabinet
- Identification of Hose Connections
- Efficient Monitoring of Cabinets in the Field
- Monitoring of Quarter Turn Actuators
- Planning and Assembly of System Solutions
- Success Stories
- I/O System Excom Creates Space in the I&C Rooms
- Zone 2 and 22 RFID
- Efficient Testing Control
- Intrinsically Safe Field Communication
- Process Control System Partnership
- Hazardous Area Remote I/O
- Dual Valve Position Feedback
- Flexibility with Fieldbus
- Asset Management with Remote I/O
- Correct Positioning with RFID in Carbid Production
- Fast conversion in restricted space
- Energy
- Food and Beverage
- Condition Monitoring of Control Cabinets
- Dough Height Inspection for Accurate Measurement
- Condition Monitoring in Storage Rooms
- Dough Thickness Control in Rolling Machines
- Identification of Food Containers
- Leading Edge Detection of Plastic Container
- Detection of Valve Position
- Container Check
- Date/Lot Code Verification
- Detection of Pipe Elbows
- Identification of Chocolate Moulds
- Detecting Refrigerated Breakfast Rolls on a Multi-Lane Conveyor
- Barcode Reading on Depalletizer Station
- Success Stories
- Grist for the Mill
- Decentralized Control Modules in Coldstore
- Track and Trace in Meat Production with RFID
- Contact-free Encoder in Potato Production
- UHF RFID in Food Distribution Center
- RFID for Chocolate production
- Distributed I/O for Food Equipment
- Remote I/O for Distilleries
- RFID and Autoclaves
- IP67 Power Supplies for Conveyors
- Transparency in Chocolate Manufacturing
- Identification in Food Product Storage
- Reliable Cap Orientation Verification in Aseptic Areas
- Clear and Tipped Bottle Detection on Depalletizer
- Clear Plastic Bottle Detection
- Frozen Food Packaging Label Inspection
- In-Line Bottle Accumulation on Single Filer
- Logistics
- Decentralized Muting of Electro-sensitive Protectice Equipment
- Container Check
- I/O Blocks Control Roller Conveyor Modules
- Fast Tag Detection at Warehouse Gates
- Item-level Detection with UHF RFID
- Preventive Maintenance on Conveyor Belts
- Detection of Transport Containers
- Level Detection in Vessels
- Identification of Cryovessels
- Identification of Mobile Containers with Handheld Devices
- Identification of Food Containers
- Tier 1 – Bumper Identification
- Condition Monitoring in Storage Rooms
- Collision Protection on Reach Stackers
- Success Stories
- Decentralised UHF RFID Solution
- Contact-free Encoder in Potato Production
- Decentralized Control Modules in Coldstore
- Speed Control via Radar Sensor QT50
- IP67 Power Supplies for Conveyors
- Modular Conveyor System
- RFID Solution for Warehouse
- RFID Guides AGV in Suspension Production
- RFID Identifies Pharmaceuticals
- UHF RFID in Food Distribution Center
- Autonomous Parking Assistance for Trucks
- Mobile Equipment
- Loading Dock Occupancy Monitoring
- Automatic Slope Compensation
- Monitoring Railcars Wheels Wirelessly
- Distribution Lines for Field Sprayers
- Reach Stacker Status With Bright Lighting Indicators
- Angle Measurement on a Field Sprayer
- Determining the Boom Angle Position
- Material Flow Monitoring on a Combine Harvester
- Vehicle at Loading Dock
- Equipment Compartment Illumination on Fire Engines
- Wireless Forklift Signaling
- STS Collision Avoidance
- Two-Axis Tilt Measurement on a Combine Harvester
- Collision Protection on Reach Stackers
- Success Stories
- Selective Asparagus Harvester
- Position Measurement with RFID and Encoder
- Speed Control via Radar Sensor QT50
- RFID Guides AGV in Suspension Production
- Block I/O Modules on Super Yacht
- Wear-free Encoder on Hopper Dredger
- I/O for Dust Suppression
- Cabinet Cooling
- Quick Disconnect Connectivity
- Automation Solutions for Extreme Cold
- Remote I/O for Cranes
- Rugged Heavy Metal Lifting
- Rollercoaster Positioning
- Mobile Machinery Solutions
- Exact Height Positioning
- Critical Angle Sensing
- Predictive Maintenance of Machine Parts at Port-Based Coal Conveying Facility
- Angle Sensor Detects Platform Lift
- Oil and Gas
- Packaging
- Decentralized RFID Package Verification
- Identification of Printing Color Cartridges
- Reliable Operation of Machines
- Monitoring of Caps in Filling Lines
- Monitoring Changeover Processes
- Identification of Test Bottles
- Level Monitoring of Ground Coffee
- Box Insert Detection
- Level Detection in Vessels
- Carton Dimensioning
- Detection of Transport Containers
- Success Stories
- Clear Container Detection
- Correct Label Verification
- Detecting Different Size Packages on a Conveyor
- High-Speed 2D Barcode Inspection
- Multicolored Reflective Package Detection
- Plastic Roll Diameter Measurement
- Tube Positioning Using a Registration Mark
- Vertical Form Fill Seal Machine Solutions
- Pharma
- End-to-End Sample Tracking with RFID
- RFID Control of Tube Connections in the Ex Area
- Decentralized package verification for pharmaceutical products
- Automate Modular Skids
- High-Speed Tablet Counting With Fiber Amplifier
- Pharmaceutical Skids with Decentralized I/O Technology
- Ex Isolation in Modular Process Plants
- I.V. Bag Liquid Detection
- Control of Valve Interfaces
- Monitoring of Quarter Turn Actuators
- Detection of Pipe Elbows
- Remote Signal I/O
- Planning and Construction of Super Skids
- Liquid Level Monitoring In A Large Tank
- Easy Connection of Field Devices
- Identification of Cryovessels
- Identification of Mobile Containers
- Identification of Mobile Containers with Handheld Devices
- Identification of Hose Connections for Precursors
- Identification of Hose Connections in Sterile Areas
- Identification of Hose Connections in Ex Zone 1
- Identification of Big Bags and Bioreactors
- Identification of Single-Use Applications
- Success Stories
- Semiconductor
- Electronic Marking Verification
- Counting Integrated Circuits
- Inspection of Two Barcodes
- Compact Safety Control
- Safeguarding Small Access Points
- Semiconductor Process Tool Illumination
- Adhesive Detection on PCB Assembly
- Wafer Center Detection with Fiber Amplifier DF-G2
- Great Detail Inspection for Mobile Electronic Devices
- Error Proofing for IC Chips loaded into Pocket Tape
- Presence and Orientation of IC Chips Seated in Nests
- Detection of Hard Disks
- Multiproduct Light-Guided Assembly Station
- LED Status Indication During Semiconductor Manufacturing
- Safeguarding Small Access Points
- Success Stories